2009 KLR Completely Dead - Kawasaki KLR 650 Forum
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post #1 of 15 Old 11-13-2013, 05:31 PM Thread Starter
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2009 KLR Completely Dead

About a week ago I washed my bike. Took it for a ride and put it up for the night. Came out next morning to ride to work and it was completely dead. No dash lights, no nothing when I turn the key to "ON". Replaced battery, checked main fuse. Still nothing when I turn the key to the "ON" position. Can someone either help or point me to a good article. Thanks!!!!
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post #2 of 15 Old 11-13-2013, 07:11 PM
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Here's a good "article:"

http://i414.photobucket.com/albums/p...0corrected.jpg

Not trying to blow you off, but . . . in your position, I'd take the wiring diagram from the link above, and a multi-meter, and start chasing wires . . .

Good luck!
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post #3 of 15 Old 11-13-2013, 07:30 PM
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I agree with Damocles. I would confirm the Battery has a decent enough charge, hook it back up and start at the ignition switch testing for power. Replaced the Battery and nothing? Start at the ignition switch my friend. Sounds like something came unplugged.

Where was this parked after washing it? I ask this as many years ago I visited a friend s son who was at college and parked my bike outside his dorm. The next morning my bike was dead...same thing..nothing when key was turned on. Blah blah blah..process of elimination and someone cut some wires under the dashboard for whatever reason who knows why. A joke?...yep..nice clean cut thru the harness
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post #4 of 15 Old 11-14-2013, 11:12 AM
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The low beam positive which it looks like powers the dash too ironically
just cooked out on my '09 and the fuse didn't last a second three in a row
while fiddling with connections. (The bike went flat out dead going down the highway.)
Coasted over with the clutch in. After I removed the tank and split the harness
open saw the melted and partially bare wire. Cut it at both ends and the bike
starts and works perfectly sans low beam and dash. Those are a simple rewire
then wrapping the harness back up the way it came, with electrical tape.

For a motorcycle it's really weird having a 28 wire bundle to begin with. The 08-09's
had some wire rubbing issues which were fixed at the factory or recalled (Mine got done)

Hope your problem is easy to trace and fix,
CheapMark

PS. Paul, crappy "joke". My friend hadda clutch cable snapped and the bolt cutters
were left by his motorcycle one fine evening back in the 80's. I had my plug wires pulled off,
the choke closed, and all switches n' petcock of my CB750 messed around
but nothing mechanically done to it I heard who did it after the fact and it was a fair
price for dropping a shot in his girl. LOL Better than getting beat up I guess. That was
long before gettin' God n' sobriety obviously.

This is my son, with whom I am well pleased." ----God

Last edited by CheapBassTurd; 11-14-2013 at 11:14 AM.
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post #5 of 15 Old 11-14-2013, 01:00 PM Thread Starter
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Thanks for the replies

Thanks for the replies. I'll see what I can do with the wiring diagram.
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post #6 of 15 Old 11-15-2013, 02:30 PM Thread Starter
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Didn't realize there were 2 - 20amp main fuses on the starter solenoid. I originally said "relay" but I think I was saying the wrong the thing. I had checked the horizontal fuse on bottom but hadn't checked the vertical fuse that was covered in a red plastic cover. The one under the red plastic was the one that was blown. Replaced it. Bike started.

HOWEVER, I rode it about a block and then the bike went dead again. Coasted to a stop. When whatever blew, a small puff of smoke came up through the front fairing by the gas tank and dash.

Questions:
1. Could the short be anywhere in the wiring harness?
2. What should I look for? Exposed wire or is it possible for the wire to short out just from being crimped by something?

(Was going to upload pic of the two fuses in the starter solenoid but I get an error message when I try to do so.)

Last edited by a9110108; 11-15-2013 at 10:28 PM.
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post #7 of 15 Old 11-15-2013, 07:15 PM
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Quote:
Originally Posted by a9110108 View Post
Didn't realize there were 2 - 20amp main fuses on the starter relay.
Typically, I don't think there are, OEM as-built.

The 20-amp main fuse powers the starter relay; a 15-amp fuse protects the headlights, and another 15-amp fuse guards the fan circuitry.

Not to say someone hasn't "upgraded" fuses to 20 amps.

Sounds like your problem resided in a blown 20-amp main fuse.

Regardless, glad you're back on the road!

---------------------

You might concern yourself regarding WHY the main fuse blew; wiring harness short-circuit most likely. Check for pinch/abrasion points; Kawasaki executed a recall for some Generation 2 wiring harnesses.

Last edited by Damocles; 11-15-2013 at 07:19 PM.
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post #8 of 15 Old 11-16-2013, 07:29 AM
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post #9 of 15 Old 11-16-2013, 04:16 PM
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a9110108,
Kinda' sounds to me, like the wires may be rubbed between the RH edge of the fuel tank and the coolant recovery bottle Bracket.
Go to www.kawasaki.com, owner info, and run your VIN to see if wiring RECALL was ever done, or go to your K dealer.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 84,000+ miles & counting
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post #10 of 15 Old 11-16-2013, 10:26 PM
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Mine was in the recall group but you now definitely have my attention.

I had the fairing off and a puff of wire smoke came up from under the tank.
Gonna do the work myself but my dealer needs to know about it. He told me
himself on the phone to wait another day to get the harness relocated under
the factory recall. Not gonna cry about it but I missed some prime riding
due to a likely overlooked fix during dealer prep and final assembly.

This is my son, with whom I am well pleased." ----God
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